As promised we are back with the 3rd and final offering in our series of how a simple coconut becomes a beautiful coir doormat! Over the last two posts, we talked about how the coconut husk is the source material from which all coir products are made. Coconut husk goes through a process of retting and de-fibering after which, cleaned and dried coir fibers of suitable length for door mats are gathered and spun into yarn. This yarn is then wound into bundles and shipped to doormat manufactures where they are assembled into a variety of coir mats of all shapes, sizes, and designs! In this final post, we learn how the doormat manufactures weave the coir yarn into your favourite doormat! There are many different kinds of weaving methods, each creating fiber for different uses. From splicing, spooling, warping to beaming and looming, each has its own process and outcome. Depending on weaving process and configuration, there are different types of weaves:
- Plain Weave is the simplest one and basically weaves one thread over the other, alternatively and continuously.
- Basket Weave is similar to Plain Weave, but the threads criss-cross, just like the weaving of a basket.
- Twill Weave is achieved by interlacing threads diagonally and is greatly used in ornamental settings.
- Three Shaft Twill Weave and Four Shaft Twill Weave are more complex and capable of creating complex patterns that are mirrored on each side of the finished product.
- Creel, known for its thin brush fiber
- Rod mats, known for their thick brush
- Fiber mats, known for their compact brush